OptiWas – Methodology for optimizing the interdependencies between additive and subtractive manufacturing

Additive manufacturing enables intricate and topology-optimized structures but exhibits limited surface quality, necessitating subsequent subtractive finishing of functional surfaces. In particular, for thin-walled components, this process chain can lead to vibrations, quality degradation, and increased machining effort. To date, a comprehensive methodology to systematically account for the interactions between additively optimized design and subtractive manufacturing is lacking. This results in extended process planning times and higher production costs for companies. OptiWas addresses this gap by transferring manufacturing knowledge into product development, aiming to make future component generations more efficient and cost-effective.

Objectives

The goal of OptiWas is to develop a methodology for the holistic optimization of the combination of additive design and subtractive manufacturing. Targeted stiffening structures are integrated into additively manufactured components to reduce vibrations occurring during machining. By analyzing real process data and feeding the results back into product development, a digital knowledge loop is created. This enables shorter development times, improved component quality, and a significant increase in productivity in hybrid manufacturing processes.

Benefits

• Process reliability – reduced vibrations, lower scrap rates
• Productivity – shorter machining times
• Quality – improved surface finish, stable tolerances

Approach

In the project, reference components with different stiffening structures are additively manufactured using laser powder bed fusion and subsequently machined. The Institute of Product Development and Equipment Construction (iPeG) is responsible for the additive manufacturing, while the IFW handles the subtractive processes. Our focus is on analyzing forces, vibrations, and surface quality during milling, from which design guidelines and evaluation functions are derived in collaboration with iPeG. This ultimately enables a systematic optimization of the interplay between additive and subtractive planning and production.

Are you also interested in a cooperation project?

Contact Fabian Schlenker via email at schlenker@ifw.uni-hannover.de or by phone at +49 511 762 18162.